JP2011063810A - Heat cell comprising exothermic composition having absorbent gelling material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an exothermic composition which rapidly reaches initial heating temperature, maintains a consistent temperature for at most twenty four hours and minimizes segregation effect or eliminates the segregation effect. <P>SOLUTION: In a heating cell comprising a particulate exothermic composition, the particulate exothermic composition includes: (a) 10 wt.% to 90 wt.% of iron powder; (b) 1 wt.% to 25 wt.% of carbon selected from a group consisting of activated carbon, non-activated carbon and a mixture of them; (c) 1 wt.% to 25 wt.% of absorbent gelling material having a median particle size of 300 μm to 800 μm; and (d) 1 wt.% to 35 wt.% of water, wherein particles of the particulate exothermic composition are combined in a pocket formed in an integrated structure comprising at least two opposed surfaces, at least one of the surfaces being oxygen permeable. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention is directed to a heating cell suitable for incorporation into a disposable heat wrap. In particular, the present invention is directed to a heating cell that includes an exothermic composition that includes an absorbent gelling material, wherein the absorbent gelling material provides improved heating.

Disposable heat wraps are becoming a popular application that applies heat to reduce temporary or chronic bodily tingling and pain discomfort. These disposable heat wraps typically include an exothermic composition for generating heat, where the exothermic composition releases metal powder, salt, so that the exothermic composition releases heat upon oxidation of the metal powder. And typically water.
The heat treatment provided by disposable heat wraps has been found suitable for the treatment of tingling and pain associated with stiff muscles and joints, nerve pain, back pain, rheumatism and the like.

  Disposable heating devices can provide sustained heat for about 1 hour to about 24 hours and other conventional such as whirlpools, hot towels, hydrocollators, heating pads and elastic compression bands It is said to be less cumbersome and more convenient than using a heat source. Disposable heating devices are further referred to as satisfactory devices that can maintain consistent and controlled temperatures; for example, referring to US Pat. No. 5,918,590, heating cells based on specific iron oxidation chemistry are It is disclosed to provide a sustained temperature that is suitable for incorporation into disposable body wraps and provides consistent, convenient, and comfortable heating for treating temporary or chronic pain.

  However, it has been found that sustained temperature consistency can be improved while sustaining temperature for up to about 24 hours. One approach to enhance the exothermic reaction is to incorporate carbon materials such as active and non-activated carbon materials. Other approaches include adding water-retainers or water-holding materials. See, for example, disposable heating devices disclosed in US Pat. Nos. 6,436,126, 6,099,556, and 5,233,981. See also the heating devices disclosed in US Published Patent Applications 2004/0042965 and 2004/0178384.

  One specific example of an exothermic composition comprising a water-absorbing polymer is disclosed in US Published Patent Application 2002/0020406. This publication describes an integrated heating medium that is integrated by mixing the exothermic agent with a water-absorbing polymer and then pressing the exothermic agent / polymer mixture with alcohol, a cross-linking agent, or a plasticizer at a specific pressure. Disclosure.

  Despite disclosure in the art of disposable heating devices that include an exothermic composition, there is still a need for a specific heating device that includes an exothermic composition that provides a controlled and sustained temperature throughout the heating period. It is known that the thermal performance of a heating cell is very sensitive to moisture levels, and a typical heating cell can contain a water concentration of about 27% or more to sustain the heating temperature of the heating cell. is there. However, the inclusion of high concentrations of water at a level of about 27% or more can make it slower to reach the desired initial heating temperature. Thus, the ability to quickly reach the desired temperature for therapeutic benefit and the ability to sustain the temperature is difficult to obtain.

  Furthermore, current heating devices contain exothermic compositions that are very susceptible to segregation. It is believed that particle size differences between compositional components can contribute to particle segregation. For example, heating devices containing exothermic compositions containing water-retainers (eg, vermiculite, wood flour, absorbent gelling materials) in combination with iron powder and carbon tend to segregate. . Typically, the particle size of a water retainer is very large compared to iron and carbon particles. For example, current heating devices can include exothermic compositions that often have a water retainer average particle to iron particle ratio of 10: 1 or higher, resulting in high particle segregation.

  Changes in the particle mixture composition due to segregation can lead to product thermal performance that is not optimal and / or different from the intended design. Therefore, maximum reaction efficiency is typically not achieved with current heating devices because an excess of exothermic composition is required to compensate for particle segregation. Typically, these heating devices include a heating cell having a relatively large volume to accommodate the excess exothermic composition.

  A heating cell comprising an exothermic composition containing an absorbent gelling material has been found to be particularly effective for quickly reaching the initial heating temperature and effective for maintaining a consistent temperature for up to 24 hours. It was done. The absorbent gelling material provides improved heating in addition to providing an exothermic composition that resists composition changes such as segregation when used in selected ratios with other composition components. I understand that. In order to minimize or eliminate segregation effects, the exothermic composition of the present invention comprises a selected particle size ratio of the absorbent gelling material and iron powder.

  The heating cell of the present invention provides a heating cell for incorporation into a disposable heating device such as a back wrap, knee wrap, body wrap, joint wrap, sanitary wrap, neck to arm wrap, etc. Has adaptive physical characteristics.

  The present invention is a heating cell containing a particulate exothermic composition, the particulate exothermic composition comprising (a) 10 wt% to 90 wt% iron powder, and (b) 1 wt% to 25 wt%. Carbon selected from the group consisting of activated carbon, non-activated carbon, and mixtures thereof, (c) 1 wt% to 25 wt% of an absorbent gelling material having a median diameter of 300 μm to 800 μm, (d 1) to 35% by weight of water, wherein the particles of the particulate exothermic composition are combined in a pocket formed in an integral structure comprising at least two opposing surfaces, the at least one surface thereof Is oxygen permeable.

  It has been found that the temperature consistency of the disposable heating device can be improved, whereby the heating device provides sustained heat for up to 24 hours. Such a heating device includes a specifically defined heating cell, which includes an exothermic composition having an absorbent gelling material. Absorbent gelling material allows retention of water in the particulate exothermic composition so that water is released at a controlled rate and results in oxidation of the iron powder, so long term with improved and sustained temperature A particulate exothermic composition is provided that provides sustained heat generation.

  Also, the particulate exothermic composition may result in segregation during processing of the exothermic composition, resulting in an exothermic composition that may not provide a consistent and controlled temperature that is maintained. Was found. In order to minimize or eliminate segregation effects, the particulate exothermic composition of the present invention is about 10: 1 to about 1:10, preferably about 7: 1 to about 1: 7, more Preferably from about 5: 1 to about 1: 5, and most preferably from about 3: 1 to about 1: 3, a selected median diameter ratio of absorbent gelling material and iron powder.

  The heating cell of the present invention contains a particulate exothermic composition. To remove temporary or chronic bodily tingling and pain discomfort, the particulate exothermic composition provides an improved and sustained temperature when the heating cell is incorporated into a disposable heating device.

  The exothermic composition of the present invention is a particulate exothermic composition. As used herein, “particulate” refers to discrete particles contained in a composition. In other words, the particulate exothermic composition as defined herein contains discrete particles, each particle having a median diameter in the range of about 25 μm (micro) to about 800 μm.

  Variations in the particle size of the particulate components of the exothermic composition as defined herein can lead to particle separation or segregation in the exothermic composition. In other words, particle size directly affects particle mobility, and the particulate components defined herein can differ in terms of their mobility, resulting in particle separation or segregation. The exothermic composition as defined herein preferably includes a particulate component having a defined median diameter range so that the exothermic composition resists particle separation or segregation. However, particulate components having a median diameter range above or below the range defined herein are considered suitable for the exothermic composition defined herein.

  As used herein, “sustained temperature” refers to about 20 seconds to about 24 hours, preferably about 20 minutes to about 20 hours, more preferably about 4 hours to about 16 hours, most preferably about 8 hours. A temperature ranging from about 32 ° C. to about 50 ° C., preferably from about 32 ° C. to about 45 ° C., more preferably from about 32 ° C. to about 40 ° C., and most preferably from about 32 ° C. to about 37 ° C. Where the maximum skin temperature and the length of time that the skin temperature is maintained at the maximum skin temperature is without any adverse events such as skin burns that may occur by using high temperatures for extended periods of time. May be appropriately selected by the individual in need of such treatment so that the desired therapeutic benefit is achieved. Maintaining the “sustained temperature” provided by the particulate pyrogenic composition of the present invention refers to acute, recurrent and / or chronic pain, including bone, muscle, and / or mention of individuals with such pain It has been shown that disposable heating devices containing particulate exothermic compositions substantially extend relief without any adverse events even after being removed from the suffering body part. .

  As used herein, the term “disposable” refers to a device that is intended to be discarded after a long period of use. In other words, a “disposable” heating device as defined herein refers to a non-preferred container after the heating device has been used long enough for the release of heat provided by the heating cell of the present invention. It is a device that means to be put in. The disposable heating device as defined herein is used until the disposable heating device has been used long enough for the release of heat for repeated use in temporary or chronic body tingling and pain relief. Can be stored in a resealable, substantially air-impermeable container.

  The heating cell of the present invention comprises a particulate exothermic composition, the particulate exothermic composition comprising the elements and limitations of the invention described herein, as well as any additional or optional ingredients described herein. , Components, or limitations, can consist of, or consist essentially of, these.

  All percentages, parts and ratios are based on the weight of the particulate exothermic composition unless otherwise specified. All such weights for the listed ingredients are based on the level of the specific ingredient and thus do not include carriers or by-products that may be included in commercially available materials, unless otherwise specified.

  All documents cited herein, including publications, patent applications, and issued patents mentioned in this specification, are hereby incorporated by reference in the relevant portions. Citation of any document is not an admission regarding the determination of being available as prior art to the present invention.

Heating cell The present invention is directed to a heating cell containing a particulate exothermic composition. The heating cell can be incorporated into a disposable heating device to provide an improved and sustained temperature to reduce temporary or chronic bodily tingling and pain. The heating cell is preferably incorporated into the disposable heating device as a plurality of heating cells.

  The heating cell is formed in an integral structure comprising a film layer substrate surface that is at least two opposing surfaces, preferably at least one surface being oxygen permeable, when filled with a particulate exothermic composition. , Filling volume, void volume, and cell volume. As used herein, filled volume refers to the volume of particulate composition in a packed heated cell. As used herein, void volume is measured by the particulate composition in the final heating cell as measured without differential pressure in the heating cell and without further stretching or deformation of the substrate material. It means the volume of the cell that is not. As used herein, cell volume means the heating cell fill volume plus the void volume. The ratio of fill volume to cell volume is about 0.7 to about 1.0, preferably about 0.75 to about 1.0, more preferably about 0.8 to about 1.0, even more preferably about 0.85 to about 1.0, most preferably about 0.9 to about 1.0.

  The heating cell can also be measured with respect to its apex. The apex of the heating cell as defined herein is greater than about 0.2 cm (centimeter) to about 1.0 cm, preferably greater than about 0.3 cm to about 0.9 cm, more preferably about 0.4 cm to It has a height of about 0.8 cm, most preferably about 0.5 cm to about 0.7 cm.

  As mentioned above, the heating cell is formed in an integral structure comprising at least two opposing surfaces, preferably a film layer substrate surface. The film layer substrate is preferably made from a film or a film laminated to a nonwoven fabric. In general, preferred films have heat sealability and can be easily thermally fused. When used, the nonwoven provides support and integrity to the film layer substrate. Examples of suitable films include polyethylene, polypropylene, nylon, polyester, polyvinyl chloride, polyvinylidene chloride, polyurethane, polystyrene, saponified ethylene vinyl acetate copolymer, ethylene vinyl acetate copolymer, natural rubber, recycled rubber, and synthetic rubber. Is mentioned. The thickness of the film layer substrate ranges from about 1 to about 300 μm and may be oxygen permeable or impermeable. Nonwoven fabrics have the preferred properties of light weight and high tensile strength, such as nylon, rayon, cellulose esters, polyvinyl derivatives, polyolefins, polyamides or polyesters, copper ammonium cellulose (Bemberg) and other high molecular weights Compounds and natural materials such as wool, silk, burlap, linen, cotton, linen, sisal or ramie are preferred. These nonwoven materials are generally described in Riedel "Nonwoven Bonding Methods and Materials", Nonwoven World, (1987), which is incorporated herein by reference in its entirety. It is. The preferred film layer substrate of the present invention is a polypropylene nonwoven sheet laminated to a poly (ethylene-vinyl acetate) or low density polyethylene (LDPE) film having a thickness of about 5 to about 100 μm. An example of a commercially available nonwoven sheet is material number W502FWH, commercially available from PGI (Polymer Group International), Waynesboro, Virginia. An example of a commercially available polypropylene / ethylene vinyl acetate (PP / EVA) film is material number DH245, which is commercially available from Clopay Plastics, Cincinnati, Ohio.

  Opposing surfaces can be made by securing two substrates together around them, so that the film side faces the inside of the pouch, envelope or pocket (the side to be filled), the nonwoven side Facing outwards to form a pouch, envelope, or pocket. The pockets can also be made from the substrate by thermoforming, mechanical embossing, vacuum embossing, or other acceptable means. Preferred for use herein is “Thermoforming”, The Wiley Encyclopedia of Packaging Technology, pages 668-675 (1986), (Marilyn Bakker). (Edit)), which is incorporated herein by reference in its entirety.

The resulting heating cell can have any geometric shape such as, for example, a disk, triangle, pyramid, cone, sphere, square, cube, rectangle, rectangular parallelepiped, cylinder, ellipse, and the like. Preferred shapes of the present invention have a cell diameter of about 0.2 cm to about 5 cm, preferably about 1 cm to about 4 cm, more preferably about 2 cm to about 3 cm, and a height of more than about 0.2 cm to about 1 cm, preferably Is greater than about 0.3 cm to about 0.9 cm, more preferably about 0.4 cm to about 0.8 cm, and most preferably about 0.5 cm to about 0.7 cm, and the resulting cell volume is about 0.0045 cm ³ Including a disk shape that is about 20 cm ³ , preferably about 0.2 cm ³ to about 11 cm ³ . Alternatively, the shape of the heating cell of the present invention may also be elongated to its geometric shape, having a major axis parallel to the substrate and having a height of about 0.2 cm to about 5 cm, preferably about 0. A cell that is greater than 5 cm to about 1 cm, has a width of about 0.2 cm to about 20 cm, preferably about 5 cm to about 10 cm, and has a length of about 1 cm to about 20 cm, preferably about 5 cm to about 10 cm. The volume is from about 0.04 cm ³ to about 2000 cm ³ , preferably from about 1.25 cm ³ to about 10 cm ³ .

Sectional area per cell heat cells of the present invention is preferably from about 0.03 cm ² ~ about 20 cm ^2, more preferably from about 0.1 cm ² ~ about 15cm ^2, even more preferably from about 1 cm ² ~ about 10 cm ^2, Most preferably from about 3 cm ² to about 7 cm ² . Heating cells having this cross-sectional area per cell are easily incorporated into body wraps or the like that provide improved compatibility with body shape.

  The heated cell of the present invention preferably has a premix of about 0.4 grams per cell to about 2.5 grams of premix per cell, more preferably about 1.0 grams of premix per cell to premix per cell. It has a premix weight of about 2.4 grams, most preferably about 1.5 grams of premix per cell to about 2.3 grams of premix per cell. A heating cell with a premix of this weight per cell also provides improved compatibility with the body shape, thereby providing even heat to the target area and improving wearer comfort It can be easily incorporated into body wraps.

  The oxygen permeability of the heating cell of the present invention is provided by selecting a film or film coating that has particularly desirable permeation properties for the film layer substrate forming the pouch, envelope, pocket, and / or covering layer. obtain. The desired transmission properties may be provided by a microporous film or by a film having pores or holes formed therein. The formation of these holes / holes may be by extrusion casting / vacuum forming or by hot needle opening. The invention also uses, for example, a taper point and at least one pin having a diameter of about 0.2 mm to about 2 mm, preferably about 0.4 mm to about 0.9 mm, preferably about 20 to about 60 pins. Thus, oxygen permeability can be provided by venting the at least one film layer substrate.

Alternatively, after the film layer substrates are bonded together, a particulate exothermic composition as defined later in this specification is placed in a pocket between them, and on one side of the heating cell, for example, a taper point and a diameter of about 0. The vent hole may be drilled using at least one pin having a diameter of 2 mm to about 2 mm, preferably about 0.4 mm to about 0.9 mm, preferably about 20 to about 60 pins. The pin is pressed into the particulate exothermic composition through one side of the heated cell material to a depth of about 2% to about 100%, preferably about 20% to about 100%, more preferably about 50% to about 100%. The The hole configuration is such that during oxidation of the particulate exothermic composition, about 0.01 ccO ₂ / min / 5 cm ² to about 15.0 ccO ₂ / min / 5 cm ² (21 ° C., 0.1 MPa ( 1 ATM)), preferably providing an oxygen diffusion of about 0.9 ccO ₂ / min / 5 cm ² to about 3 ccO ₂ / min / 5 cm ² (21 ° C., 0.1 MPa (1 ATM)). Preferably, the upper covering film layer is provided with vent holes, but the lower covering film layer and / or both may be provided with vent holes.

  The heating cell of the present invention may incorporate components optionally delivered through the skin, where optional components include active aromatic compounds, inert aromatic compounds, pharmaceutically active agents or other therapeutic agents, and These mixtures are mentioned. The optional component can be incorporated into the heating cell as a separate substrate layer or can be incorporated into at least one film layer substrate. Such active aromatic compounds include, but are not limited to, menthol, camphor, eucalyptus, and mixtures thereof. Such inert aromatic compounds include, but are not limited to, benzaldehyde, citral, decanal, aldehyde, and mixtures thereof. Such pharmaceutically active / therapeutic agents include antibiotics, vitamins, antiviral agents, analgesics, anti-inflammatory agents, antipruritics, antipyretics, anesthetics, antifungal agents, antibacterial agents, and mixtures thereof. However, it is not limited to these. The heating cell may also include a separate substrate layer or may be incorporated into at least one film layer substrate, a self-adhesive component and / or a sweat-absorbing component.

Exothermic Composition The heating cell of the present invention comprises a particulate exothermic composition that provides an improved sustained temperature when the heating cell is incorporated into a disposable heating device such as a disposable body wrap. The particulate exothermic composition includes a particulate premix composition and a brine solution.

  The constituents of the particulate premix composition typically include iron powder, carbon, absorbent gelling material, and water, which are described below. Similarly, typical components of a brine solution include metal salts, water, and optionally a hydrogen gas inhibitor such as sodium thiosulfate. In general, the exothermic composition as defined herein comprises a particulate premix composition and is prepared by rapidly administering a brine solution to the premix to form the heated cell of the present invention. A typical heating cell of the present invention comprises about 0.4 grams of premix per cell to about 2.5 grams of premix per cell, and about 0.4 grams of preline solution per cell to about brine solution per cell. Can contain 1.5 grams. Accordingly, the exothermic composition of the present invention has from 0.8 grams to about 4.0 grams per cell, preferably from about 1.5 grams to about 3.5 grams, more preferably from about 2.5 grams to about 3 grams. A total cell weight of 0.0 grams can be included.

  The rate, duration, and temperature of the exothermic oxidation reaction of the particulate exothermic composition are controlled as desired by changing the contact area with air, more specifically, by changing the oxygen diffusion / permeability. it can. Other methods for modifying the exothermic reaction include, for example, selecting the components within the composition by selecting the specific components described later in this specification, modifying the component particle size, etc. Is mentioned.

  Illustratively, one particular method of modifying the exothermic reaction is to add iron powder having a median diameter of about 200 μm and an absorbent gelling material having a median diameter of about 300 μm, where absorption The median diameter ratio of the conductive gelling material and the iron powder is 1.5: 1. This selectivity ratio between the absorbent gelling material and the iron powder has been shown to provide an exothermic composition that exhibits fast initial heating temperatures and long term heat that was difficult to achieve with current exothermic compositions. Current exothermic compositions contain high levels of moisture that provide water to interstitial particle voids, which are believed to limit oxygen flow and slow down the initial heating temperature rate. It has been found that the exothermic composition comprising the selected median diameter ratio absorbent gelling material and iron powder eliminates excess water from the interstitial particle voids, resulting in a faster initial heating temperature. It was.

Iron Powder The particulate exothermic composition of the present invention comprises from about 10% to about 90%, preferably from about 30% to about 88%, more preferably from about 50% to about 87% by weight of the composition. Containing one or more iron powder components at a range of concentrations.

  The particulate exothermic composition as defined herein is believed to release heat upon oxidation of the iron powder. Iron is known to be the anode for electrochemical reactions related to the exothermic oxidation of iron. There are no specific restrictions on the purity, type, size, etc. of the iron powder as long as it can be used to generate heat with conductive water and air. For example, iron powders having a median diameter of about 50 μm to about 400 μm, preferably about 100 μm to about 400 μm, more preferably about 150 μm to about 300 μm, have been found suitable for use herein. It was.

  The median diameter of the iron powder and any other particulate component defined herein can be determined using a sieving method such as the method disclosed in ASTM method B214. In general, the particles are sorted through a series of sieves of different sizes and the weight fraction of the particles retained on each screen is measured. The cumulative weight distribution curve is then generated using the weight fraction of the particles in each screen. A cumulative weight distribution curve is then generated by plotting the particle size against the weight percent of particles added cumulatively below the particle size retained on the largest sieve. The median diameter is determined from the cumulative weight distribution curve, where the median diameter is defined as the particle size corresponding to 50% of the cumulative weight. For details on creating the cumulative weight distribution curve, see “Methods of Presenting Size Analysis Data”, Particle Size Measurement, pages 153-156, 4th edition, Terrence. Allen), (1990), which is incorporated herein by reference in its entirety. Explaining the sieving method, about 100 g +/− 0.1 g of test sample is now placed on the top mesh screen of a US standard sieve stack having a larger screen opening than the screen below it. Place the lid on the top screen, then secure the sieve stack to a mechanically operated sieve shaker such as a Tyler RoTap shaker and run the shaker for 15 minutes And mechanically reproduce the shaking action that occurs when manually sieving, and tapping the sieve stack during the shaking process to help the particles fall through the mesh screen, and after 15 minutes of shaking, each mesh screen The material collected above is weighed to the nearest 0.1 gram (g). The sum of the weights of all fractions should not be less than 99.7% by weight of the test sample. The weight of the fraction retained on each sieve is expressed as a percentage of the weight of the test sample in units of 0.1%. Any fraction of 0.04% by weight or less of the test sample shall be reported as “TRACE”. Any fraction greater than 0.05% by weight of the test sample is reported as 0.1% unless indicated to be reported in the second decimal place. If there is no fraction, it shall be reported as 0.0%. Thereafter, the median diameter is determined.

  Preferably, the particulate exothermic composition comprises a selected median diameter ratio of an absorbent gelling material and iron powder as defined herein below. The exothermic composition comprising this selected median diameter ratio component provides a heating cell that has improved heating and the ability to resist composition changes such as resistance to particle segregation. It was shown that. The median diameter ratio of the absorbent gelling material to the iron powder is typically about 10: 1 to about 1:10, preferably about 7: 1 to about 1: 7, more preferably about 5: 1 to about 1: 5, most preferably in the range of about 3: 1 to about 1: 3.

  The heating cell of the present invention is typically small compared to current heating cells and cannot use excessive levels of exothermic composition to compensate for particle segregation effects. In fact, adding an excessive level of exothermic composition can lead to significant changes in the thermal performance of the heating cell. By using iron powder having a median diameter within the range specified in this specification, particularly by using iron powder in a ratio of the combination of absorbent gelling material and iron powder, particle segregation action is reduced. It was found to be reduced. The reaction rate of the exothermic composition is controlled by the porosity of the exothermic composition, in other words, the rate at which the heating cell generates heat is present in the particle packing mode (ie, interstitial particle void volume) and the exothermic composition. It is thought that it is influenced by the amount of water to be used. The iron powders defined herein provide a low filling mode, but the absorbent material prevents temporary or chronic body tingling and pain because it prevents water from entering the particle voids. Resulting in a heating cell that exhibits fast initial heating temperatures and long term heat.

  Non-limiting examples of suitable sources of the iron powder of the present invention include cast iron powder, reduced iron powder, electrolytic iron powder, scrap iron powder, sponge iron, pig iron, wrought iron, various steels, iron alloys, these iron sources Processed types, and mixtures thereof. Sponge iron is preferred.

  Sponge iron is one source of iron powder, and sponge iron can be particularly advantageous due to its high internal surface area. Since the internal surface area is an order greater than the external surface area, the reactivity may not be controlled by the particle size. Non-limiting examples of commercially available sponge iron include M-100 and F-417, which are described in U.S. Pat. S. A. Available from Hoeganaes Corporation in New Jersey.

Sponge iron is a material used in the steel making industry as a basic source for the production of steel. Although not intended to be limited to any manufacturing method, sponge iron exposes hematite (Fe ₂ O ₃ ) iron ore in crushed form to a reducing gas environment at temperatures somewhat below the blast furnace temperature. May be manufactured. Sponge iron including the production of sponge iron is disclosed in U.S. Pat. Nos. 2,243,110, 2,793,946, 2,807,535, 2,900,247, and second. , 915,379, 3,128,174, 3,136,623, 3,136,624, 3,136,625, 3,375,098 3,423,201, 3,684,486, 3,765,872, 3,770,421, 3,779,741, 3, 816,102, 3,827,879, 3,890,142, and 3,904,397, the disclosures of which are hereby incorporated by reference. Incorporated in the description.

  Although oxygen is required to cause the iron oxidation reaction, an internal oxygen source is not required in the heating cell of the present invention, but without changing the scope of the present invention, Or may be incorporated into the particulate exothermic composition at the time of its preparation. Oxygen sources used for the purposes of the present invention include air and oxygen of various purity made artificially. Of these oxygen sources, air is preferred because it is the most convenient and inexpensive.

Carbon The particulate exothermic composition of the present invention ranges from about 1% to about 25%, preferably from about 1% to about 15%, more preferably from about 1% to about 10% by weight of the composition. Containing one or more carbon components at a concentration of

  Non-limiting examples of carbon suitable for use herein include activated carbon, non-activated carbon, and mixtures thereof. The carbon component has a median diameter of about 25 μm to about 200 μm, preferably about 50 μm to about 100 μm. Activated carbon is preferred.

  Activated carbon serves as the cathode for electrochemical reactions related to the exothermic oxidation of iron. However, the cathode function can be extended by further using non-activated carbon powder, ie carbon blended to reduce costs. Therefore, the above carbon mixtures are useful in the present invention as well.

  Activated carbon has a very porous internal structure and has a particularly good oxygen adsorption function. In fact, when the activated carbon is wet, the activated carbon has the ability to adsorb oxygen very well, so that the activated carbon can function as a catalyst in the electrochemical reaction.

  Furthermore, activated carbon can absorb water well and can serve as a water retention material. Furthermore, activated carbon can adsorb odors such as those caused by the oxidation of iron powder.

  Activated carbon prepared from coconut shell, wood, charcoal, coal, bone coal, etc. is suitable for use herein, but other such as animal products, natural gas, fats, oils, and resins Those prepared from these raw materials are also useful in the particulate exothermic composition of the present invention. Although there is no restriction | limiting in the kind of activated carbon to be used, A preferable activated carbon has a favorable oxygen adsorption function. Examples of commercially available activated carbon include activated carbon available from MeadWestvaco, Covington, Virginia (USA).

  In order for the exothermic composition to warm up faster while maintaining thermal duration, the exothermic composition must have more absorbent gelling material than activated carbon. It was shown that if there is less absorbent gelling material than activated carbon, the exothermic reaction becomes sensitive to moisture content and does not warm up quickly. Without being bound by theory, this is due to competition to obtain moisture between the absorbent gelling material and the activated carbon, in order for the exothermic reaction to proceed, the activated carbon must absorb oxygen. It is believed that it needs to be wet enough to function as a catalyst.

  Further, in order to maximize interstitial particle void volume, the amount of carbon in the particulate exothermic composition as defined herein must be minimal. Carbon is typically the finest particle component, and excess carbon will eventually fill the interstitial particle void volume. Because the absorbent gelling material is used at relatively high levels, it has been found that the amount of carbon required for the exothermic reaction is significantly lower than the amount used in current exothermic compositions. Thus, carbon is primarily used for its catalytic activity and minimally for its water retention properties.

  Since low levels of carbon provide a premix that quickly absorbs the brine solution, low levels of carbon are also highly desirable for the heating cell manufacturing method of the present invention. This significantly increases the speed of the manufacturing method of the heating cell as defined herein.

Absorbent Gelling Material The particulate exothermic composition of the present invention is about 1% to about 25%, preferably about 1% to about 15%, more preferably about 1% to about 10% by weight of the composition. Contains one or more absorbent gelling materials at a concentration by weight.

  Absorbent gelling materials suitable for use herein are capable of physically or chemically retaining water within the particulate exothermic composition of the present invention. In particular, the absorbent gelling material has the function of gradually supplying water to the iron powder component, where water is released at a controlled rate. Without being bound by theory, the absorbent gelling material can prevent or inhibit water from entering or being maintained in the interstitial voids of various particles of the exothermic composition. As a result, it is believed to help prevent or suppress flooding.

  Non-limiting examples of suitable absorbent gelling materials include absorbent gelling materials that have fluid-absorbing properties and are capable of forming a hydrogel upon contact with water. One specific example of such an absorbent gelling material is a hydrogel-forming absorbent gelling material based on a polyacid, such as polyacrylic acid. The polymeric material that forms this type of hydrogel is one that absorbs such fluid and forms a hydrogel when in contact with a liquid such as water. In general, these preferred absorbent gelling materials are substantially water-insoluble, slightly cross-linked, partially neutralized, hydrogel-forming polymeric materials prepared from polymerizable unsaturated acid-containing monomers. Will include. In such materials, the polymer component formed from unsaturated acid-containing monomers may contain a complete gelling agent, or may be grafted to other types of polymer moieties such as starch or cellulose. . A starch material grafted with acrylic acid is of this latter type. Accordingly, specific suitable absorbent gelling materials include hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, polyacrylates, maleic anhydride copolymers, and combinations thereof. Polyacrylate and acrylic acid grafted starch materials are preferred. Non-limiting examples of commercially available polyacrylates include those available from Nippon Shokubai, Chatanooga, USA (Tennessee).

  The absorbent gelling material has a median diameter of about 300 μm to about 800 μm, preferably about 400 μm to about 800 μm, more preferably about 500 μm to about 800 μm. Absorbent gelling materials having a median diameter of 300 μm or more have been shown to minimize or eliminate segregation effects. Reducing segregation effects provides an improved sustained temperature so that the desired therapeutic heat benefit is achieved without any adverse events such as skin burns. Reducing segregation effects enables rapid production of disposable heating devices that include multiple heating cells that provide up to 24 hours of therapeutic heat.

  As described hereinabove, the particulate exothermic composition as defined herein preferably has a selected median diameter ratio absorbent gelling material and iron powder. Exothermic compositions comprising these components with a defined selected median diameter ratio do not exhibit minimal segregation or segregation and are consequently intended for the desired therapeutic thermal benefit It has been shown that an exothermic composition is obtained that satisfies the thermal behavior.

  In addition to the absorbent gelling material, the particulate exothermic composition of the present invention can optionally include other water retaining materials having capillary function and / or hydrophilic properties. These optional water retention materials may comprise from about 0.1% to about 25%, preferably from about 0.5% to about 20%, more preferably from about 1% to about 15% by weight of the composition. Can be included in the particulate exothermic composition at a concentration in the range. Non-limiting examples of such optional water retention materials include vermiculite, porous silicate, wood powder, wood flour, cotton, paper, vegetable material, carboxymethylcellulose salt, inorganic salt, and mixtures thereof. Absorbent gelling materials and optional water retention materials are further described in US Pat. Nos. 5,918,590 and 5,984,995, which are incorporated herein by reference. .

Metal salt The particulate exothermic composition of the present invention comprises from about 0.5% to about 10%, preferably from about 0.5% to about 7%, more preferably from about 1% to about In the concentration range of 5% by weight, one or more metal salts are included.

  Metal salts suitable for use herein include metal salts that serve as reaction promoters for activating the surface of the iron powder to facilitate the oxidation reaction with air, and to prevent corrosion reactions. Electrical conductivity is provided to the exothermic composition for retention. In general, there are several suitable alkali, alkaline earth and transition metal salts that can be used alone or in combination to maintain the corrosion reaction of iron.

  Non-limiting examples of suitable metal salts include sulfates, chlorides, carbonates, acetates, nitrates, nitrites, and mixtures thereof. Specific non-limiting examples of sulfates include ferric sulfate, potassium sulfate, sodium sulfate, manganese sulfate, magnesium sulfate, and mixtures thereof. Specific non-limiting examples of chlorides include cupric chloride, potassium chloride, sodium chloride, calcium chloride, manganese chloride, magnesium chloride, cuprous chloride, and mixtures thereof. Cupric chloride, sodium chloride, and mixtures thereof are preferred metal salts. Examples of commercially available sodium chloride include sodium chloride available from Morton Salt, Chicago, Illinois (USA).

Water The particulate exothermic composition of the present invention comprises water at a concentration ranging from about 1% to about 35%, preferably from about 5% to about 33% by weight of the composition. Water suitable for use herein is obtained from any suitable source. For example, tap water, distilled water, or deionized water, or a mixture of any of these are suitable for use herein.

  It is known that the thermal performance of a heating cell is very sensitive to moisture levels, and a typical heating cell can contain a water concentration of about 27% or more to sustain the heating temperature of the heating cell. . However, inclusion of highly concentrated water at a level of about 27% or more can result in a slower initial desired heating temperature. Thus, the ability to quickly reach the desired temperature for therapeutic benefit and the ability to sustain the temperature is difficult to obtain. However, the particulate exothermic composition of the present invention not only provides a heating cell that is very effective in maintaining a sustained, controlled, and consistent temperature, but also provides a heating cell with a fast initial heating temperature. Has also been found to provide a heating cell that provides the desired therapeutic heat benefit without any adverse events such as skin burns. This is achieved by incorporating a sufficient weight ratio of absorbent gelling material and water so that the particulate exothermic composition has a high internal water retention and a high interstitial particle void volume. The particulate exothermic composition of the present invention comprises a water to absorbent gelling material in a weight ratio of about 3: 1 to about 9: 1 by weight, preferably about 4: 1 to about 7: 1 by weight. including.

  In addition, current heating cells typically contain high levels of water to increase the length of time that the heating temperature of the heating cell is sustained. Thus, the exothermic composition of the present invention can contain high levels of water and is configured at a lower cell weight level than current heating cells. Accordingly, the exothermic composition of the present invention is more effectively utilized at high water concentrations and a smaller exothermic composition is required to obtain the desired heating temperature duration.

Optional Component The exothermic composition of the present invention comprises one or more other optional components known or otherwise effective for use in the exothermic composition, wherein the optional component is a composition described above herein. It may further be included provided that it is physically and chemically compatible with the element or otherwise does not unduly impair the stability, aesthetics, or performance of the product. Other optional components suitable for use herein include coagulant aids including corn syrup, maltitol syrup, crystallized sorbitol syrup, and amorphous sorbitol syrup, microcrystalline cellulose, ultrafine Dry binders, including elements such as cellulose, maltodextrin, sprayed lactose, co-crystallized sucrose and dextrin, modified glucose, mannitol, pregelatinized starch, dicalcium phosphate, and calcium carbonate, elements chromium, manganese, copper, and said elements Oxidation reaction enhancers, including compounds, including, but not limited to, sodium thiosulfate, sodium sulfite, sodium hydroxide, potassium hydroxide, sodium bicarbonate, sodium carbonate, calcium hydroxide, calcium carbonate, and propion Sodium acid listed Inorganic and organic alkali compounds, and hydrogen gas inhibitors including alkaline weak acid salts, wood dust, natural cellulose fragments including cotton linters and cellulose, synthetic fibers in the form of fragments including polyester fibers, such as expanded polystyrene and polyurethane Foamed synthetic resins, silica powder, porous silica gel, fillers such as inorganic compounds including sodium sulfate, barium sulfate, iron oxide and alumina, anti-caking agents such as tricalcium phosphate and sodium silicoaluminate, As well as materials such as mixtures thereof. Such components include thickeners such as corn starch, potato starch, carboxymethylcellulose and alpha starch, and surfactants such as those included in anionic, cationic, nonionic, bipolar and amphoteric species. Can be mentioned. Still other optional components, including bulking agents such as metasilicates, zirconium, and ceramics, and mixtures thereof, may optionally be included in the compositions or articles herein. Other optional components are included in the particulate exothermic composition at a concentration range of about 0.01% to about 35%, preferably about 0.1% to about 30% by weight of the composition. Can do.

Method of Manufacture The particulate exothermic composition of the present invention may be prepared by any known or otherwise effective technique suitable for providing an exothermic composition that provides a therapeutic thermal benefit. The particulate exothermic composition of the present invention is preferably prepared using conventional blending techniques. A suitable method of blending the components of the particulate exothermic composition of the present invention is more fully described in US Pat. No. 4,649,895 (issued March 17, 1987 to Yasuki et al.). This description is incorporated herein by reference.

  A typical technique for blending the components of the particulate exothermic composition is to add carbon to a blender or mixer, add a small amount of all the water, and then mix the carbon / water combination. It is done. Usually enough water is added to help the blend and avoid expanded corrosion. Mixing is stopped and the absorbent gelling material is added to the carbon / water combination. Mixing is resumed until all components are thoroughly mixed, after which iron powder is added and mixed. The composition is then thoroughly mixed and blended to form a particulate premix. Sodium chloride, optionally a hydrogen gas inhibitor such as sodium thiosulfate, and the remaining water are mixed separately to form a brine solution, which is then added to the iron powder premix and heated cell of the present invention. The particulate exothermic composition used in the construction is formed.

  Typically, individual heating cells are prepared by adding an amount of particulate premix composition to a pocket in a film layer substrate sheet, such as a pocket in a polypropylene nonwoven / LDPE film layer substrate sheet. Can. In this method, water or brine is rapidly administered to the top of the premix composition and a flat sheet of polypropylene nonwoven / poly (ethylene-vinyl acetate) film layer substrate is added to the poly (ethylene-vinyl acetate). The film side is placed on the cell facing the LDPE film side of the preformed pocket containing the sheet. The film layers of the two sheets are secured together using low heat to form an integral structure. The obtained heating cell contains a particulate exothermic composition enclosed in a pocket between two film layer base sheets.

  Alternatively, individual heating cells can be prepared using vacuum to form pockets. That is, the particulate premix composition is placed on top of the film layer substrate surface directly above the mold and a vacuum is used to draw the film layer substrate surface into the mold. The particulate premix composition falls into a vacuum forming pocket and is held in place by the vacuum used for the particulate premix composition at the bottom of the mold. The brine solution is then rapidly administered to the top of the premix composition. Thereafter, the second film layer substrate surface is placed on the first film layer substrate surface such that the particulate exothermic composition is between the two surfaces. Thereafter, the particulate exothermic composition is encapsulated between the first and second film layer substrate surfaces.

  The resulting heating cell can be used alone or as a plurality of heating cells, where the heating cell can be incorporated into various disposable heating devices such as disposable body wraps. Typically, a body wrap has means for holding the wrap in place around various parts of the body such as the knee, neck, back, etc., and can include a number of shapes and shapes, where The holding means includes a fastening device such as a two-part hook and loop fastening system that can be resealed.

  As described in the aforementioned US Pat. No. 4,649,895, previously incorporated herein by reference, preferably the resulting heating cell is used to prevent oxidation reactions from occurring until desired. In a secondary air impervious package. Alternatively, an air impermeable removable adhesive strip can be placed over the vent holes in the heating cell so that when entering the strip, the air enters the heating cell and activates the oxidation reaction of the iron powder. .

  The following examples further describe and demonstrate embodiments within the scope of the present invention. These examples are presented for illustrative purposes only, and many modifications are possible without departing from the spirit and scope of the invention, and should be construed as limiting the invention. is not. All exemplified concentrations are weight-weight percent unless otherwise specified.

  The particulate exothermic composition exemplified below is prepared using conventional blending techniques to form the particulate exothermic composition, and the resulting composition is used to construct the heating cell of the present invention. Provided.

  A premix is prepared by adding activated carbon and water to a blender or mixer such as a Littleford Day Mixer and mixing for about 10 minutes. Thereafter, an absorbent gelling material such as polyacrylate is added and the mixture is mixed for about 10 minutes. Next, iron powder, such as sponge iron, is added to the mixer and the resulting premix is mixed for about 5 minutes.

  Add approximately 2.2 grams of the resulting premix composition to a pre-formed pocket (which was thermoformed to form the pocket) in a sheet of polypropylene nonwoven coated with a film of LDPE To do.

  Next, a brine solution is prepared by adding water, a metal salt such as sodium chloride, and optionally sodium thiosulfate to the mixer and mixing for about 15 minutes. The resulting brine solution is then rapidly administered onto the premix composition to constitute one or more heated cells of the present invention.

Thereafter, a flat polypropylene nonwoven sheet coated with poly (ethylene-vinyl acetate) is placed on a heating cell and heated to adhere to the bottom sheet. Cut the material around the heating cell to provide 2.5 cm of excess material around the periphery of the cell. 100 pins with a diameter of approximately 0.5 mm are simultaneously pressed to one side of the cell until approximately 100% penetrates the exothermic composition, but do not penetrate the bottom sheet. This perforation process results in a diffuse O ₂ permeability of about 1 cc / min / 5 cm ² (21 ° C., 0.1 MPa (1 ATM)). Immediately after the brine is added to the particulate composition, the cell begins to generate heat, so the top and bottom sheets are secured and the final heated cell is immediately packaged in an airtight secondary package for future use. To do.

The resulting heating cell can be incorporated into disposable heating devices including disposable body wraps such as back wraps, knee wraps, joint wraps, sanitary wraps, neck to arm wraps, and the like.

  While specific embodiments suitable for use with the particulate exothermic composition of the present invention have been described, those skilled in the art will recognize that various changes and modifications of the present invention can be made without departing from the spirit and scope of the invention. It will be obvious. All such modifications that are within the scope of this invention are intended to be covered by the appended claims.

Claims (10)

A heating cell containing a particulate exothermic composition, wherein the particulate exothermic composition comprises:
(A) 10% to 90% by weight of iron powder;
(B) 1% to 25% by weight of carbon selected from the group consisting of activated carbon, non-activated carbon, and mixtures thereof;
(C) 1 wt% to 25 wt% of an absorbent gelling material having a median diameter of 300 μm to 800 μm;
(D) 1% to 35% by weight of water, wherein the particles of the particulate exothermic composition are combined in a pocket formed into an integral structure comprising at least two opposing surfaces, at least one of which A heating cell in which one surface is oxygen permeable.   The heating cell according to claim 1, wherein the ratio of the median diameter of the absorbent gelling material to the median diameter of the iron powder is 10: 1 to 1:10, preferably 3: 1 to 1: 3. .   The heating cell according to claim 1 or 2, wherein the particulate exothermic composition contains 50 wt% to 87 wt% of iron powder.   The heating cell according to claim 1, wherein the iron powder has a median diameter of 50 μm to 400 μm.   The iron powder is selected from the group consisting of cast iron powder, reduced iron powder, electrolytic iron powder, scrap iron powder, pig iron, sponge iron, wrought iron, steel, iron alloy, and mixtures thereof, preferably the iron powder is sponge iron The heating cell according to any one of claims 1 to 4, wherein   The particulate exothermic composition comprises 1% to 15% by weight of an absorbent gelling material, the absorbent gelling material being hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, polyacrylate, maleic anhydride The heating cell according to any one of claims 1 to 5, which is a hydrogel-forming polymer material selected from the group consisting of acid-based copolymers and mixtures thereof.   The particulate exothermic composition is 0.5% to 10% by weight of a metal salt selected from the group consisting of alkali metal salts, alkaline earth metal salts, transition metal salts, and mixtures thereof, preferably chloride. The heating cell according to any one of claims 1 to 6, further comprising a metal salt selected from the group consisting of sodium, cupric chloride, and mixtures thereof. The cross-sectional area of the heat cell is ^{2cm 2 ~10cm} 2, heat cell according to any one of claims 1 to 7.   The heating cell according to any one of claims 1 to 8, wherein the total cell weight of the heating cell is 0.8 gram to 4.0 gram.   10. The heating cell is incorporated into a disposable heating article selected from the group consisting of a back wrap, a knee wrap, a neck wrap, a sanitary wrap, a joint wrap, and a neck to arm wrap. The heating cell according to any one of the above.